0294_A_TARS-CSI-MAIN PROPULSION DIESEL ENGINE - MAJOR OVERHAUL (20K HRS) (SCSI).docx

ABSTRACT:

The purpose of this item is to provide the OEM labor, technical services, material, and industrial support to accomplish 20,000 hour scheduled maintenance of Caterpillar D399TA Engines.

REFERENCES/ENCLOSURES:

References:

Caterpillar Maintenance Management Schedule for Marine Engines (SEBU6102). Available commercially.

Caterpillar Operation and Maintenance Manual (SEBU5698). Available commercially.

Caterpillar Service Manual (SEBR0511). Available commercially.

Enclosures:

Caterpillar D399TA Main Propulsion Diesel Engine Model Data Diesel Engine Maintenance Start-up and Dormant Start-up Readiness Assessment (One Checklist per Diesel Engine)

ITEM LOCATION/DESCRIPTION:

Location/Quantity:

Location: Main Machinery Room (3-53-0-E).

Quantity: One (1) Main Diesel Engines.

Item Description/Manufacturer's Data:

Caterpillar Engine Model D399TA.

GOVERNMENT FURNISHED EQUIPMENT/MATERIAL/SERVICES:

Government Furnished Equipment (GFE): None.

Government Furnished Material (GFM):

Lube oil as required.

Engine coolant additive as required.

Government Furnished Services (GFS): None.

NOTES:

The contractor and all subcontractors, regardless of tier must consult the General Technical Requirements (GTR) to determine applicability to this work item. In performance of this work item, the contractor and all subcontractors regardless of tier must comply with the requirements of all applicable GTRs including but not limited to GTRs 1 through 7, 22, 23, 28, and 29.

The contractor and all subcontractors regardless of tier are advised to review other work items under this contract to determine their effect on the work required under this work item. Many of the definitions relating to performance of this work item are found in Work Item 001.

The vessel's Chief Engineer or representative will secure the jacketwater heaters and drain the engine jacketwater system. Inform the Chief Engineer, in a timely manner, when the engine jacketwater system is ready to be refilled and tested for water tightness. See paragraph 7.13 for deionized water provided under Work Item 011.

The vessel's Chief Engineer or representative will drain the engine lube oil sump pan to its lowest level allowed by the installed piping arrangement. It is the responsibility of the contractor to drain any residual oil and clean the sump. Upon completion of work notify the Chief Engineer when the engine is ready for re-filling of oil. See paragraph 6.7 for crank case inspection requirement.

The following definitions explain the terminology used in Section 7 for the service that is performed during an overhaul. These terms are used by Caterpillar to define diesel engine inspection and repair and complement definitions in Work Item 001:

Inspect – Inspect the components according to the instructions that are in Caterpillar reusability publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029, “Index of Publications on Reusability or Salvage of Used Parts”.

Rebuild – The component is reconditioned by OEM or authorized representative in order to comply with reusability guidelines.

Replace – The service life of the part is exhausted. The part may fail before the next maintenance interval. The part must be replaced with a part that meets functional specifications. The replacement part may be a new CAT part or a CAT remanufactured part. Some parts have an associated core charge for which credit is received when returned to a CAT dealer.

QUALITY ASSURANCE REQUIREMENTS:

At least one member of ship's force will be assigned to assist with quality assurance efforts whenever main diesel work is being accomplished.

Make known to all personal working on the engine and generator unit, that electrical and electronic controls and devices are present and may require necessary precautions and isolations that must be protected from damage during the overhaul period.

Enclosure 2.2.1 for engine specific model and serial number data. This information is required for identification of correct parts for completion of work identified in section 7.0.

Chief Engineer or MSC Port Engineer will inspect crank case upon notification by contractor that work is complete.

STATEMENT OF WORK REQUIRED:

Tagout all required systems and equipment. Drain and dispose of any liquid in accordance with all federal, state and local regulations.

Only OEM authorized or qualified representatives will be permitted to temporarily remove, inspect, refurbish, and reinstall main diesel engine components.

The lead Original Equipment Manufacturer (OEM) representative is to remain on-site from the beginning of work until completion of work with satisfactory dock and sea trails. If there is a need to change the lead OEM representative during this scheduled maintenance action, the shipyard quality assurance department is to schedule a turnover meeting with the departing and arriving lead OEM representatives, shipyard quality assurance personnel and MSCREPs in attendance to ensure a proper turnover is accomplished.

At the halfway point of the engine overhaul, the contractor representative will contact ABS to conduct an inspection for credit towards the unit's Continuous Machinery Survey. The unit will not be closed until approval is granted by the ABS. Provide the attending MSC Port Engineer and Chief Engineer with a minimum of 24-hour notice as to when the unit will be open and ready for inspection by the ABS Surveyor.

Provide all tools and material required, including, but not limited to special tools, rags, degreaser, lubricant and loctite for accomplishment of all elements of this work item. Ship’s force will NOT provide any tools.

Only OEM parts are to be used in the accomplishment of work under this work item.

Temporarily remove aftercoolers from the engine and prepare for transport. Protect fins and cooler openings. Transport aftercoolers to OEM authorize facility. Clean and test aftercoolers in accordance with manufacturer’s requirements. Transport back to vessel and reinstall on engine.

Accomplish the requirements associated with 20,000 operating hour overhaul as found in Reference 2.1.1 and applicable Caterpillar Technical Service Bulletins and OEM guidance, including removing existing and installing:

Cylinder heads, complete with valves, springs, guides and pre-chambers.

Pistons, Piston Pins and Retainers Cylinder Liners Main Bearings, Complete (Including Thrust) Connecting Rod Bearings, Complete Rebuilt/Remanufactured (Core Exchange) Jacket Water Pump Cylinder Fuel Injection Valves Front and Rear Cover Seals and Gaskets Front and Rear Hydromechanical Seals (Directional) Lube Oil Cooler (non-Removable), Complete Core Exchange Fuel Pump Assemblies Fuel Pump Injection Pump Group Yoke Screw and Locknut Jacket Water Thermostats Double Wall Fuel Injection Lines Pre-Lube Pump Fuel Injection System and Governor Main Oil Pump and Relief Valve Governor Drive Group Actuator, Linkages, Manual Shutdown Linkages Vibration Dampener Gear Train Driven Unit Alignment, Reduction Gear Rocker Arm Assembly and Bushings Including Rocker Arm Buttons and Springs Exhaust Pyrometers, Complete with Leads Rebuild Existing Saltwater Pump with new Impeller (4L6220), Rebuild Kit (1W7066), Elbow Assy (5L1549) Fuel Transfer Pump All Filters Including Lube Oil (Six (6)), Fuel Oil (Seven (7)) and Air Filters (Two (2)) Crank Case Breathers Clean and check all valve mechanism assemblies using Reference 2.1.4 for guidance.

Test and adjust the new fuel nozzles prior to installation using Reference 2.1.4 for guidance.

Check and adjust the fuel timing using Reference 2.1.4 for guidance.

Adjust all piston cooling jets to the proper spray angle.

Ensure installed shields cover fuel and oil line connections per SOLAS regulations.

Ensure marine classification society approved tape is installed over fuel and oil line connections per SOLAS regulations.

Verify the engine to reduction gear alignment is within specification using Reference 2.1.4 for guidance. Submit an “as found” condition report.

Inspect all electrical connections, test low lube oil pressure and high jacket water temperature safety shutdown devices, exhaust pyrometer leads and readouts, wire standoffs and chafing protections installed on the engine and provide a condition report stating general condition and any abnormal findings.

Using engine model and serial number found in Enclosure 2.2.1, check for any Technical Service Bulletins, recalls or warranty repairs that may be required on the engines.

Provide labor and material to temporarily install valves, fittings, and hoses (as required) to assist ship's force in filling the engines with GFM lube oil identified in paragraph 4.2.1 and deionized water provided under WI 011.

NOTE: SHIP'S FORCE WILL TREAT ENGINE FRESH WATER WITH GFM ADDITIVE IDENTIFIED IN 4.2.2.

Inspection/Test:

Test all engine alarms and safety devices. Record all alarm and safety device set points and submit to MSCREP.

Notify the Chief Engineer and the attending Port Engineer when the overhauled engine unit is ready to be tested during dock and sea trials. Notify the ABS Surveyor in order to attend the final testing so credit can be given for the Continuous Machinery Survey on the unit. Record cylinder operating temperatures, fluid operating temperatures and pressures during testing. Submit an “as found” condition report.

Prior to engine start-up the checklist in Enclosure 2.2.2 is to be completed. This evolution is to be accounted for in the scheduling of work under this item and related items.

During the operational testing verify proper protection is provided by installed engine heat screening and insulation to protect from fire in the event of oil or fuel spray. Use a thermal imaging camera to note any surfaces hotter than the maximum SOLAS requirement of 220 Deg C (428 Deg F). Inspect for the below noted conditions and provide a condition report for any noted discrepancies.

Screening and insulation are in place and mounted correctly.

Gaps in screening where fuel or oil spray can contact hot surfaces.

Where insulation mats are used, evaluate if an oil leak can contaminate or soak the material and be a fire risk.

Inspect insulation and screening around exhaust bellows and expansion joints for exhaust smell, discoloration and cracks.

Inspect insulation and screening for oil contamination or soaking. Any insulation or screening found in this condition should be noted in a condition report for replacement.

Test overhauled engine during dock and sea trails.

Reports:

When inspection, service and testing reveal any deficiency a condition report is to be submitted to the MSCREP with recommended repairs and parts required. Submit three (3) typewritten copies and one (1) electronic copy in Portable Document Format (PDF).

Provide the MSCREP with a completed electronic report for each engine no more than seven (7) days after the completion of all work. Submit three (3) typewritten copies and one (1) electronic copy in Portable Document Format (PDF). The report will contain the following, at minimum:

Engine operating hours and serial number.

Photographs of the engine condition at disassembly and any unusual conditions.

Description of any abnormal or usual conditions found during maintenance.

Measurements taken and recorded. "As-found", "As-released" and acceptable ranges for measurements are to be listed in the report.

Include comments on any defects found in arrangements for removals and lifting of engine components.

Include a listing of any additional special tools found to be needed for successful maintenance on engine.

Include a listing of all parts used during maintenance. The parts list to include the Sub-Assembly drawing number and Caterpillar part number.

Include a listing of all parts included in the parts kits or ordered and not used as well as items turned over to ship’s Force.

Crankshaft Deflection readings Crankshaft Thrust readings Engine to reduction gear alignment readings Valve lash and timing measurements with OEM acceptable limits.

Fuel valve injection pressure before and after testing.

Painting/Lagging:

Prepare, prime, paint and restore all new, soiled, and disturbed surfaces to match surrounding surfaces. Renew lagging where existing lagging was removed.

Paint new cylinder heads to match existing engine color prior to installation.

Manufacturer's Representative:

Provide the services of an OEM authorized field service representative to accomplish all work and testing on the diesels identified in paragraph 3.0 ensuring compliance with the manufacturer’s standards and performance specifications.

This work item requires maintenance and repair actions to be performed on a MSC ship critical safety item. Only original equipment manufacturer (OEM) authorized technical field service providers or MSC qualified non-OEM technical field service providers and OEM authorized or MSC qualified non-OEM parts shall be used to accomplish the requirements of this work item for this ship critical safety item including oversight and guidance on all aspects of equipment as-found condition inspection, removal, disassembly, reassembly, repairs, modifications, reinstallation, and testing as applicable. The technical service provider is to attend dock and sea trials.

Contractors interested in gaining MSC qualification as a non-OEM parts and/or service provider should visit this website for qualification and submittal requirements: https://www.msc.usff.navy.mil/Business-Opportunities/Contracts/Qualification-for-Items-Critical-to-Shipboard-Safety-on-MSC-Vessels/.

Possible Source(s):

Timberline Tractor & Marine, Inc.

CLEVELAND, OH. USA

POC: Mr. Joe Scholtz Cell: +13308131228 Office: +13309666623 Fax: +13309666615 Toll Free:+18008272702 jrscholtz@nls.net Provide the MSCREP with a signed letter of qualification from the Original Equipment Manufacturer and certificate of training for the field service representative for the equipment listed in paragraph 3.0 prior to the start of any work.

All reports and checklists are to be completed and signed by the person who carried out the inspection and maintenance work and countersigned by the Company’s representative.

Assist ship’s force in completion of Enclosure 2.2.2 checklist.

Prepare and submit an Engine Start-Up Certification to MSCREP within one (1) day of work completion. This document certifies that work is compete and the engine may be started.

Preparation of Drawings: None.

GENERAL REQUIREMENTS: None additional.

ENCLOSURE 2.2.1

CATERPILLAR D399TA MAIN PROPULSION DIESEL ENGINE MODEL DATA

MPDE 1A

Model: D399TA USNS Salvor

( ARS 50 52 )

Serial Number: 91B01491 0294 - 16

USNS/USS ________________________ Hull No: _______

Diesel Engine Examined for Start-up: ____________________________________

Port / Shipyard: __________________________ Date: ________

72 Hours (notional) Prior to Dock Trial (Machinery Space Turnover)

48 Hours (notional) Prior to Startup

24 Hours (notional) Prior to Startup

Pre-Start

Chief Engineer Port Engineer